JP2001183054A - Refrigerator and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an efficient recycling method for a foamed urethane which is used as a heat insulation material for a waste refrigerator. SOLUTION: A stock solution of foamed urethane containing a regenerated polyol, a fresh polyol and water in the amount of 0.1-5% based on the total amount of the above polyol is injected and foamed in the space between the outer box and the inner box of a refrigerator.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a refrigerator manufactured using a raw material liquid of urethane foam containing a regenerated polyol and a method for manufacturing the same.

[0002]

2. Description of the Related Art Disposal of waste refrigerators is becoming an important social issue, for example, with the recent increase in environmental protection and the enactment of the law on recycling of large household appliances including refrigerators. Considering recycling of a waste refrigerator, it is a constituent material used as a heat insulating material of the refrigerator and occupying about 10% of the weight of the refrigerator, and treatment of bulky urethane foam is a very important issue. BACKGROUND ART Conventionally, urethane foam waste discharged from a refrigerator or the like provided for use has been mainly disposed of by disposal after being collected. However, it has become necessary to promote the reuse of urethane foam from the viewpoint that the capacity of the disposal site is approaching the saturation state and from the viewpoint of environmental protection. From a recycling point of view, it is the most desirable form to return the discarded material to the original product and reuse it. Therefore, urethane foam discharged from waste refrigerator
It has become necessary to establish a method for reusing in refrigerators.

[0003] Since foamed urethane is a thermosetting resin, it is difficult to melt and regenerate it like thermoplastic resins. Therefore, various reuse methods have been conventionally studied. First, for example, a method in which a crushed product of urethane foam described in JP-A-52-0090162 is reused as a filler by mixing with a urethane stock solution and refoaming. No. 34926 describes a press molding method in which waste material of urethane foam is crushed or cut, a binder is applied thereto, and a mixture obtained is subjected to hot compression molding. Thirdly, for example, JP-A-10-152578
As described in the publication, this is a chemical decomposition method in which urethane foam is decomposed using a certain solvent, and the resulting foam is used as a part of the raw material of urethane foam again.

[0004] On the other hand, when considering reuse as a heat insulating material for a refrigerator, the following methods can be used in each of the above methods. In the first method, when injecting urethane foam as a heat insulating material for a refrigerator, simultaneously mix the urethane foam pulverized material,
Pour into the space consisting of the inner and outer boxes. In the second method,
The plate-like material obtained by press molding is applied as a heat insulating wall of a refrigerator. In the third method, a part of the urethane foam raw material liquid is returned to the manufacturing process of the refrigerator insulated box and reused.

[0005]

Although it is an important method for recycling urethane foam when considering recycling of a refrigerator, the above-mentioned conventional method has the following disadvantages. In the first method, the density of the urethane foam powder is small, the mixture is difficult to mix due to the difference in density from the urethane stock solution, and the mixing state tends to be uneven. Therefore, the location where the urethane powder is localized becomes brittle, and the strength of the refrigerator box cannot be exhibited. In addition, there is a drawback that if the urethane powder is mixed in a category where there is no problem in quality, the mixing ratio is considerably reduced. In the second method, the sheet is once formed into a plate-like material and then attached to a refrigerator as a heat insulating wall. In addition, in the second method, it is difficult to form a closed cell that produces a heat insulating effect, and considering the function as a heat insulating material of a refrigerator,
Difficult to apply. The third method is a method of making a part of the raw material again, so it can be dealt with without basically changing the conventional manufacturing process, and is an economically advantageous method. In order to maintain it, the mixing ratio of the regenerated raw materials was kept low, and there was a drawback that they could not be used effectively.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and has as its object to obtain a refrigerator in which urethane foam is reused without deteriorating quality and a method of manufacturing the same.

[0007]

According to a first aspect of the present invention, there is provided a refrigerator having an outer box, an inner box, and a space between the outer box and the inner box, and injecting a raw material liquid of urethane foam into the space. In the refrigerator formed by foam filling, the raw material liquid of the urethane foam contains a regenerated polyol, a new polyol, and water, and the amount of water is the entire polyol obtained by combining the new polyol and the regenerated polyol. 0 for the amount of
1 to 5%.

In the refrigerator according to the present invention, the amount of the regenerated polyol is 1 to 50% based on the total amount of the polyol including the new polyol and the regenerated polyol.

Further, the refrigerator according to claim 3 comprises an outer box,
An inner box, a box formed by the outer box and the inner box, a plurality of partition walls for partitioning the box into a plurality of storage rooms, and foaming in a space between the outer box and the inner box. A plurality of inlets provided on the back of the refrigerator for injecting a urethane raw material liquid, and a raw material of urethane foam to be injected from an inlet provided behind a portion where the plurality of partition walls are densely provided. The liquid has a larger proportion of the recycled polyol contained therein than the urethane foam raw material liquid injected from an injection port provided behind a portion where the plurality of partition walls are roughly provided.

Further, the refrigerator according to claim 4 comprises an outer box,
An inner box, a box formed by the outer box and the inner box, a partition wall provided at a position higher than a central portion of a refrigerator that divides the box into two storage compartments, A plurality of inlets provided on the back of the refrigerator for injecting the urethane foam raw material liquid into the space between the inner box, and the plurality of inlets are provided in the up and down direction of the partition wall, and upward. The urethane foam raw material liquid injected from the provided injection port has a larger ratio of the regenerated polyol contained than the urethane foam raw material liquid injected from the downwardly provided injection port.

Further, in the refrigerator according to claim 5, the partition wall is provided in a height range of 800 to 1100 mm.

Further, the refrigerator according to claim 6 comprises an outer box,
An inner box, a box formed by the outer box and the inner box, a first partition wall provided at a position higher than a central portion of a refrigerator that partitions the box into two storage rooms, A second partition wall provided between the partition wall and the bottom surface of the refrigerator, and a plurality of inlets provided on the rear surface of the refrigerator for injecting the urethane foam raw material liquid into a space between the outer box and the inner box. The plurality of inlets are provided in the vertical direction of the first partition wall, and the urethane foam raw material liquid to be injected from the upwardly provided inlet is injected from the downwardly provided inlet. The ratio of the regenerated polyol to be contained is larger or the same as that of the raw material liquid of the urethane foam.

Further, the refrigerator according to claim 7 includes an outer box,
An inner box, a box formed by the outer box and the inner box, a first partition wall provided at a position higher than a central portion of a refrigerator that partitions the box into two storage rooms, A second partition wall provided between the partition wall and the refrigerator bottom surface, and a third partition wall provided between the first partition wall and the second partition wall,
A plurality of inlets provided on the back of the refrigerator for injecting the urethane foam raw material liquid into a space between the outer box and the inner box, wherein the plurality of inlets are arranged in a vertical direction of the first partition wall. Is provided, the raw material liquid of the urethane foam injected from the injection port provided in the upward direction, compared to the raw material liquid of the urethane foam injected from the injection port provided in the downward direction, the ratio of the contained recycled polyol is small, Or the same.

In the refrigerator according to the present invention, the height of the first partition wall is set in the range of 800 to 1100 mm, and the height of the second partition wall is set in the range of 300 to 500 mm.

Further, the refrigerator according to claim 9 comprises an outer box,
An inner box, a box formed of the outer box and the inner box, a plurality of doors covering a front surface of the box, and a raw urethane foam liquid in a space between the outer box and the inner box. And a plurality of inlets provided on the back of the refrigerator for injecting, the raw material liquid of the urethane foam to be injected from the inlet provided behind the largest door is foamed from the inlet other than the inlet. The ratio of the contained recycled polyol is smaller than that of the urethane raw material liquid.

Further, in the refrigerator according to the tenth aspect, the raw material liquid of the urethane foam injected from the injection port provided behind the largest door does not contain the recycled polyol.

[0017] In the method for manufacturing a refrigerator according to the eleventh aspect, a step of mixing the regenerated polyol and a new polyol is performed, and 0.1 to 5% of water is mixed with respect to the total amount of the mixed polyol to form a mixed solution. And a step of injecting a raw material liquid of the urethane foam containing the mixed liquid into a space provided between an outer box and an inner box of the refrigerator, foaming and filling the same, and manufacturing a refrigerator. .

Further, a method of manufacturing a refrigerator according to claim 12 comprises a step of crushing a box made of urethane foam;
A step of separating urethane foam from the crushed refrigerator, a step of pulverizing the separated urethane foam lump, a step of heating by adding a polyol and a catalyst to the pulverized urethane powder, and distilling the product after heating, A step of producing a regenerated polyol by filtration, and a step of injecting a raw material liquid of the urethane foam containing the regenerated polyol into a space provided between an outer box and an inner box of the refrigerator and foam-filling the same to produce a refrigerator It is provided with.

[0019]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 FIG. 1 shows a process of producing a refrigerator from the production of a heat insulating box for a refrigerator, regenerating a polyol based on urethane after disposal, and using the regenerated polyol. The polyol 1 and the isocyanate 2, which are the raw material liquids of the urethane foam, are mixed using the high-pressure foaming machine 3 (Step 1, hereinafter, the step is described as S).
A mixed liquid (urethane liquid) generated by the high-pressure foaming machine 3 which is a raw material liquid of urethane foam is caused to flow into a space formed between an outer box and an inner box of the refrigerator, and the space is foam-filled to insulate the refrigerator. A box 4 is made (S2). Various components, such as shelves and refrigerator doors, are attached to the refrigerator insulation box 4 so that the refrigerator 5
(S3; not shown). The attachment of each component in S3 may be performed before S1 or S2. The refrigerator 5 is discarded (S4) to become a waste refrigerator 6. Waste refrigerator 6
In the case where the crushing and collecting method is used as the treatment, the crushed material, the thermoplastic resin part to be recycled, and the like are removed (S5; not shown) and crushed by being put into the crusher 7 (S6). The crushed urethane foam becomes a massive urethane foam 8. The urethane lump 8 is made of urethane lump, metal,
It is separated into other resins (S7; not shown). The separated urethane mass is put into the crusher 9 and further crushed (S
8). The crushed urethane foam lump is powdery urethane powder 1
It becomes 0. Urethane powder 10, polyol 11, catalyst 1
1 ′ is put in the reaction tank 12, mixed and heated (S9). The decomposition liquid 13 in the reaction tank 12 is supplied to a distillation apparatus 14 or a filter 14 ′.
Distillation and filtration to remove low-boiling substances and solids (S1
0), producing recycled polyol 15; Using a predetermined amount of the regenerated polyol 15 as the polyol 1, a refrigerator using the regenerated polyol is produced through steps S1 and S2. As described above, it is possible to manufacture a refrigerator with excellent quality and economical reuse of waste urethane, and to realize an ideal recycling process of returning the waste discharged from the refrigerator to the refrigerator again.

Although the flow chart of FIG. 1 describes that the produced regenerated polyol 15 is continued to be used as the polyol 1, if this flow is continued too many times, the quality such as the strength of the urethane foam is reduced. Come. Instead of using the recycled polyol 15 generated in this flow, it is also possible to use a recycled polyol generated in another flow for the polyol 1 or use only a new polyol for the polyol 1. The components of the polyol 1 (mixing ratio of the regenerated polyol, etc.) are adjusted in accordance with the intended quality such as the strength of the refrigerator heat insulating box. In addition, the above uses a waste refrigerator's insulation box to manufacture a new refrigerator's insulation box.However, it is also possible to use waste urethane other than refrigerators for refrigerators, and to use waste urethane other than refrigerators for refrigerators. It is also possible to reuse it.

FIG. 1 will be described in detail. Urethane foam is generally produced by reacting a polyol with an isocyanate. Before reacting the polyol with the isocyanate,
Add foaming agent, water, catalyst and foam stabilizer. As the type of the blowing agent, fluorocarbons such as HCFC141b and hydrocarbons such as cyclopentane are used. When foaming is performed in S1 of FIG. 1, it is necessary to perform high-speed and high-speed collision mixing in order to surely react and foam the two liquids of polyol 1 and isocyanate 2, but a high-pressure foaming machine 3 is generally used. The urethane liquid (raw urethane liquid) mixed in the high-pressure foaming machine 3 is discharged into the space formed by the outer box and the inner box of the refrigerator, and is heated by the reaction to generate heat.
The foaming agent contained in the urethane liquid evaporates and fills while foaming the space. The foamed and solidified urethane foam is adhered and solidified to a contacting member such as an outer box of a refrigerator to form a heat insulating box 4 of the refrigerator.

Various components, for example, a shelf, a refrigerator door, a refrigerator door pocket, a cooler, a compressor, and the like are attached to the heat insulating box 4 (S3), and the refrigerator 5 shipped as a product is provided to the user by the user. After the life is completed, it is discarded (S4). The discarded refrigerator 6 is collected and processed in a factory that recycles waste home electric appliances. A general method of the processing will be described. The waste refrigerator 6 collects necessary parts, for example, chlorofluorocarbon and refrigerating machine oil in a crushing and collecting method, and removes a compressor, a door gasket magnet, a recyclable thermoplastic resin part, etc., which are difficult to crush, in advance. (S5) The crusher 7 is charged. Here, the urethane foam, which is a heat insulating material, is crushed into urethane blocks 8 having a size of about several tens of mm (S6). The urethane block 8 is separated from the urethane block, metal (eg, iron such as an outer box), and other resins (eg, ABS resin such as an inner box) using a wind separator or the like (S).
7). The separated urethane lump is crushed by a pulverizer 9 to further reduce the bulk, thereby forming a powdery urethane powder 10 (S8). This urethane foam is crushed (S6) and crushed (S6).
8) It is desirable to provide a device for collecting a blowing agent such as fluorocarbons generated in the step of performing the above process, and to appropriately treat the ozone layer-depleting substances and greenhouse gases without releasing them into the atmosphere.

Next, a process for producing a regenerated polyol based on the generated urethane powder 10 will be described. Methods for producing a regenerated polyol include a polyol decomposition method, an amine decomposition method, a hydrolysis method, a tandem chemolysis method, and an ammonia decomposition method. Here, the most effective method for decomposing a polyol is described. The polyol decomposition method decomposes a urethane bond using a compound having a hydroxyl group such as ethylene glycol. It is desirable that the urethane powder 10, which is a raw material of the regenerated polyol 15, be finely pulverized in order to efficiently promote the decomposition reaction. For example, when urethane powder of about several mm is used, the decomposition reaction time is reduced to about 1/5 as compared with the case where urethane lump of about several tens mm is used for the reaction. Urethane powder 10 is mixed with polyol 11 and catalyst 11 ′ in reaction vessel 12.
And heated while stirring (S9). The polyol 11 to be charged may be a simple substance such as ethylene glycol or a mixture of substances having different numbers of hydroxyl groups. As the catalyst 11 ', for example, an alkali catalyst such as potassium hydroxide, an amine catalyst, or the like is used. Heating (S9)
It is carried out at 150 to 250 ° C. for one to several hours. After cooling, the generated decomposed liquid 13 is subjected to distillation under reduced pressure in a distillation apparatus 14 to remove low-boiling substances such as water, and the filter 14 ′ is pressurized or the like.
To remove solids (S10). The properties of the regenerated polyol 15 thus obtained can vary depending on the type and form of the polyol 11 used in the reaction and the ratio of the urethane powder 10 and the polyol 11 to be charged.

The recycled polyol 15 produced under the conditions set to have properties suitable for refrigerator insulation is mixed with a new polyol and used again as a refrigerator insulation material as polyol 1. FIGS. 2 to 7 show the mixed forms of the regenerated polyol. For the polyol 1 to be foamed (see FIG. 1), it is necessary to add a prescribed amount of a foam stabilizer 17, a catalyst 18, water 19, and a foaming agent 20 required for foaming in addition to the polyol to prepare a polyol system liquid, that is, a polyol 1. There is. FIG. 2 shows a new polyol 16 and a recycled polyol 15 as foaming agents 17b and 17a, catalysts 18b and 18a, water 19b,
3 is a method of mixing the foaming agent 20 after the addition of 9a, and FIG.
c, the catalyst 18c and the water 19c are added, and the foaming agent 20 is mixed after the regenerated polyol 15 is mixed. FIG.
A method in which a foam stabilizer 17d, a catalyst 18d, and water 19d are added and a foaming agent 20 is mixed. FIG. 5 shows a method in which a foam stabilizer 17e and a catalyst 18e are added to a new polyol 16 in advance, and after mixing the regenerated polyol 15 with water 19e. FIG. 6 shows a method of adding the foaming agent 20 to the new polyol 16, adding a foam stabilizer 17f, a catalyst 18f, and water 19f to the new polyol 16, adding only water 19f 'to the regenerated polyol 15, and mixing the two liquids. Foaming agent 20
FIG. 7 shows the method of FIG.
The process after mixing 5 is different, and a new polyol 1
Assuming that the regenerated polyol 15 is previously mixed in a fixed ratio to 17g, 17 g of a foam stabilizer, 18 g of a catalyst, and 19 g of water are added. After mixing the regenerated polyol 15, 19 g 'of water is further added, and The above six regenerated polyol mixing forms as described above are conceivable, but the method to be used is determined from the viewpoints of production and quality control.

In the production process of urethane foam, polyol 1
Management of water content is an important item. Since water is an item that affects the heat insulation, strength, and fluidity of urethane foam, it is necessary to adjust the water content of the polyol to an appropriate water amount after inspection. From the viewpoint of moisture control, the regenerated polyol mixing step is desirably the steps shown in FIGS. 2, 4, 5, 6, and 7. In particular, after mixing the new polyol 16 and the regenerated polyol 15, water (19d, 19e) is used. , 19
4, 5, and 7, which are steps for adding g ′), are desirable. The recycled polyol 15 is distilled in the production process (S10).
Removes low-boiling substances, while removing water. Therefore, the generated regenerated polyol 15 often has insufficient water content as a raw material of a refrigerator insulation material. Therefore, it is necessary to add an appropriate amount of water 19 after inspecting the water content of the recycled polyol 15 and the new polyol 16 or the water content of the entire polyol in which the recycled polyol 15 and the new polyol 16 are mixed. Normally, when a new polyol 16 is supplied from a raw material maker to a refrigerator maker, a prescribed amount of the foam stabilizer 1
7, the catalyst 18 and the water 19 are often added. In such a case, if the recycled polyol 15 is directly mixed with a new polyol 16 and used in the production of a refrigerator, a shortage of water corresponding to the mixture of the recycled polyol 15 occurs, and mainly a lack of fluidity and strength is caused. In particular, in order to cope with the recent complicated form of the refrigerator, it is important to secure the fluidity. In order to secure the fluidity, the insufficient water 19 is added after the new polyol 16 and the regenerated polyol 15 are mixed. It will be. At that time, the amount of the water 19 to be added is determined based on the result of the water content test of the generated regenerated polyol, the water content of the new polyol to be mixed, and the mixing ratio of the regenerated polyol, and is 0.1 to It is added in the range of 5%. By increasing the amount of water, urea bonds generated by the reaction between water and isocyanate increase, and the strength increases. However, the reaction that produces a urea bond is
Since the calorific value of the reaction is high and the reaction rate at the time of foaming increases, the upper limit of the amount of water added is about 5%.

FIG. 8 shows the compressive strength of foamed urethane obtained by mixing the recycled polyol 15 produced by the above-described method of FIGS. 2 to 7 with a new polyol 16 and foam molding. The horizontal axis indicates the mixing ratio (%) of the recycled polyol 15, and the vertical axis indicates the compressive strength of the urethane foam for each mixing ratio. Compressive strength decreases from around the point where the mixing ratio exceeds 20%. Therefore, in order to maintain the conventional quality, it is necessary to limit the mixing ratio to about 20% or increase the overfilling ratio to increase the strength. However, increasing the overfill rate is not economically advantageous because it increases the injection amount.

FIG. 9 is a schematic view of a two-door refrigerator. (A) is a front view of a refrigerator, (b) is a side view of a refrigerator. In the case of this type of refrigerator, a partition wall 25 exists between a storage room 23 having an upper small door and a storage room 24 having a lower large door. An inlet 20 for injecting a urethane raw material liquid is provided on the back of the refrigerator.
a and 20b are provided two each. Due to the difference in the distance between the bottom surface 22 and the partition wall 25 and the distance between the ceiling surface 21 and the partition wall 25, and the size of the box of the refrigerator, the difference in the size and weight of the door, etc. Is easier to deform. Therefore, since the strength is reduced by mixing the recycled polyol, the recycled polyol is included from the inlet 20b behind the door, which is installed on the lower storage room 24 side of the largest door that is easily deformed. By injecting no urethane raw material liquid and injecting the urethane raw material liquid mixed with the regenerated polyol 15 only from the inlet 20a provided on the opposite upper storage chamber 23 side, without affecting the refrigerator box body strength And recycled polyol 15 can be used. However, if the mixing ratio of the recycled polyol that does not affect the strength is known as shown in FIG. 8, the mixed ratio of the recycled polyol of the urethane raw material liquid supplied from the inlet 20a on the upper storage chamber 23 side that is located at the opposite position. The urethane raw material liquid mixed with the regenerated polyol may be supplied from the inlet 20b on the lower storage room 24 side with a large door within the upper limit of the mixing ratio that does not exceed the above and does not cause a decrease in strength.

Next, an embodiment of the present invention will be described for each type of refrigerator. FIG. 10 is a schematic view of a refrigerator in various modes. In the refrigerator of FIG. 10A, a partition wall 25 is provided at a position of 800 mm to 1100 mm from the bottom surface 22 in the height direction, and is separated into two upper and lower storage rooms 23 and 24. The height of the partition wall 25 is set to a height that does not make the upper storage room 23 difficult to use.
Also, the reason why the height of the partition wall 25 is given a width is that the partition wall 25 is provided at a higher position when the overall height of the refrigerator is high, for example, when it is about 1650 mm or more, and the overall height of the refrigerator is reduced. When it is low, for example, when it is about 1600 mm or less, the partition wall 25 is provided at a low position. Bottom 2
Due to the difference between the distance between the partition wall 25 and the partition wall 25 and the distance between the ceiling surface 21 and the partition wall 25, the lower storage room 24 having a large distance is more easily deformed than the upper storage room 23 having a small distance. Therefore, it is possible to inject the urethane raw material liquid mixed with the regenerated polyol from the upper inlet 20a (see FIG. 9), but to mix only the new polyol from the lower inlet 20b (see FIG. 9). Inject the raw material liquid or
A raw material liquid that does not exceed the mixing ratio of the recycled polyol of the urethane raw material liquid to be injected into the upper injection port 20a and is within the upper limit of the mixing ratio at which the strength does not decrease is injected.

The refrigerator shown in FIG.
A second partition wall 26 is provided between the base 22 and the bottom 22 at a position of 300 mm to 500 mm in the height direction from the bottom 22.
(A) partitioning the storage room 24, three storage rooms 23, 2
9 and 30. The height of the second partition wall 26 is set to such a height that the lower storage room 30 does not become difficult to use. This refrigerator is partitioned by a first partition wall 25 into an upper storage room 23, which is a small storage room, and a lower storage room 24, which is a large storage room. By partitioning by the two partition walls 26, a beam of the lower storage room 24 is formed and the strength is increased. Therefore,
From the lower injection port 20b, it is possible to input a urethane raw material liquid whose mixing ratio of the regenerated polyol is higher than that in the case of FIG. 10 (a) and is smaller than or equal to the raw material liquid input from the upper injection port 20a. it can.

The refrigerator shown in FIG. 10C is obtained by dividing the storage room 29 of the refrigerator shown in FIG. In the refrigerator of FIG. 10D, the storage room 32 of FIG. 10C is vertically partitioned by the fourth partition wall 28 into the storage room 3.
3 and 34, and the refrigerator of FIG.
(C) The storage room 331 is formed by partitioning storage rooms 35 and 36 in the vertical direction with the fourth partition wall 28. In these refrigerators, a second partition wall 26 and a third partition wall 27 or a second partition wall 26, a third partition wall 27, and a fourth partition wall 28 form a ramen structure. Therefore, the portion where the ramen structure is formed becomes the strongest.
Contrary to (b), the lower injection port 2 than the regenerated polyol mixing ratio of the urethane raw material liquid supplied from the upper injection port 20a.
The mixing ratio of the recycled polyol in the urethane raw material liquid to be charged from 0b can be increased. Also, the lower inlet 20
The mixing ratio of the recycled polyol of the urethane raw material liquid to be charged from b may be the same as the upper one. As an example of the storage room in FIG. 10C, 23 is a refrigerator room, 31 is a vegetable room, 32
Denotes a first freezing room, and 30 denotes a second freezing room. FIG.
As an example of the storage room of (d), 23 is a refrigerator room, 31 is a vegetable room, 33 is an ice making room, 34 is a switching room, and 30 is a freezing room. As an example of the storage room in FIG. 10E, 23 is a refrigerator room, 35 is an ice making room, 36 is a switching room, 32 is a vegetable room, 30
There is a freezer.

It is preferable to inject a raw material liquid in which the ratio of the regenerated polyol is changed depending on the position of the partition wall. For example, FIG.
In (d) and (e), a raw material liquid having a reduced ratio of the regenerated polyol is supplied to the inlet 20a corresponding to the upper part where the partition wall is in a rough state, and to the lower part where the partition wall is in a dense state. By using a raw material liquid having a large ratio of the regenerated polyol for the injection port 20b to be used, an effective regenerated polyol can be used with respect to a required box strength. As described above, by increasing the number of partition walls in the refrigerator and increasing the strength of the refrigerator, it is possible to increase the mixing ratio of the recycled polyol to the new polyol of the urethane raw material liquid to be injected into the space formed by the outer box and the inner box of the refrigerator. . Thus, a highly reliable refrigerator using recycled materials can be manufactured, and the recycling rate of waste refrigerators increases. By changing the mixing ratio of the regenerated polyol according to the form of the refrigerator, it is possible to obtain a refrigerator in which urethane foam is reused and a method of manufacturing the refrigerator without deteriorating the quality. Table 1 shows FIG.
3 shows a change in refrigerator box strength depending on a recycled polyol mixing ratio in the refrigerator of FIG. X is the upper inlet 20
a is the mixing ratio (%) of the recycled polyol of the urethane raw material liquid to be charged into a, Y is the mixing ratio (%) of the recycled polyol of the urethane raw material liquid to be injected into the lower inlet 20b, and Z is the refrigerator box strength index.

[0032]

[Table 1]

The refrigerator box strength index Z is a relative index when the state of the urethane raw material liquid without the mixture of the regenerated polyol is 100, and the smaller the value, the lower the strength.
The pass line was 90, and the pass ratio of the recycled polyol shown in Table 1 that was passed was underlined. According to Table 1, the raw material liquid in which the mixing ratio of the regenerated polyol was suppressed to about 20% at which the strength did not decrease as shown in FIG. 8 was injected from the injection port 20a provided above the first partition wall 25, Even if a raw material liquid in which the mixing ratio of the regenerated polyol is increased to 50% is injected from the injection port 20b provided below the partition wall, the strength of the refrigerator as a whole is not affected so much that there is no quality problem. It turns out that the level can be secured. In this refrigerator, when the amount of the raw material liquid injected from the upper inlet 20a and the amount of the raw liquid injected from the lower inlet 20b are substantially the same, the raw material liquid in which X is 20% and Y is 50% is injected. Sometimes, the most regenerated polyol is used. This is because the ramen structure is formed by the second partition wall 26, the third partition wall 27, and the fourth partition wall 28 as described above, and the portion is strengthened. By changing the mixing ratio of the recycled polyol, the recycled polyol can be used effectively. As described above, the refrigerator in which the first partition wall 25 is provided at a position in the vicinity of the center with respect to the height direction of the refrigerator or more is described.
If there is a first partition wall 25 near the center, lower the mixing ratio of the recycled polyol of the urethane raw material liquid injected from the upper injection port, or mix the recycled polyol of the urethane raw material liquid injected from the lower injection port in some cases. What is necessary is just to raise a rate or to provide another partition wall used as a beam.

In addition, the regenerated polyol often takes on a blackish brown color due to the heat history received in the manufacturing process. Therefore, when the mixing ratio of the regenerated polyol is changed by the injection port 20, the color tone of the heat insulating material becomes different from that of the refrigerator. The heat insulating material near the inlet 20 into which the raw material liquid having a high mixing ratio of the regenerated polyol is injected becomes dark brown. However, since the heat insulating material is usually covered with the outer case and the inner case, it is not visible to the user and there is no problem in design.

The position where the urethane foam in the refrigerator is filled will be described with reference to a sectional view of FIG. A urethane raw material liquid is injected into the space defined by the outer box and the inner box from inlets 20a and 20b provided on the back of the refrigerator, and filled with urethane foam 41 as a heat insulating material (hatched portion). Not only the refrigerator box but also the refrigerator door is filled with the urethane foam 41 as a heat insulating material (hatched portion), and the above-described recycled polyol can be used for this refrigerator door. In addition, this refrigerator
It is partitioned by three partition walls 55, 56, 57 to form four storage chambers 51, 52, 53, 54. This storage room is, for example, 51 a refrigerator room, 52 a freezer room, 53 a vegetable room, and 54 a refrigerator room. The fan 4 cools the cool air of the cooler 43.
The cold air is circulated in the refrigerator by sending to each storage room at 2 (open arrow) and returning from each storage room to the cooler 43 through the cool air return air passages 45, 48, and 49 (black arrow). .

As described above, the injection port 2 is located above the first partition wall 25.
Although two refrigerators 0a and two injection ports 20b below the refrigerator were provided at a total of four places, in order to uniformly fill the space formed by the outer box and the inner box of the refrigerator with urethane foam, The position of the inlet 20 in the height direction is such that the height of the refrigerator is divided into four parts, and the inlet 20b is set at a position approximately one-fourth from the bottom surface 22 and 3/3.
The inlet 20a is preferably provided in the vicinity of the position 4 and is not necessarily divided above and below the first partition wall 25.
Further, the position may be changed upward or downward according to the installation condition (vertical, horizontal, diagonal placement, etc.) of the refrigerator box at the time of injecting the urethane raw material liquid. For refrigerators of about 250L or more, two places in the height direction, two on each side
Normally, a total of four points each are used. However, at the time of foaming, the space formed by the outer box and the inner box is evacuated and then the urethane liquid is injected, so that only one injection port 20 is possible. is there. The inlet 20 has a good rear surface, bottom surface, ceiling surface, etc. of the refrigerator, which is difficult to see from the user, and may be provided in the vicinity of the machine room where the compressor is installed. Further, the position of the inlet 20 may be at the rear of the partition wall or at the back of each storage room.

[0037]

According to the first aspect of the present invention, there is provided a refrigerator in which an outer box, an inner box, and a space between the outer box and the inner box are provided, and a material liquid of urethane foam is injected into the space and foamed and filled. At
The raw material liquid of the urethane foam contains a regenerated polyol, a new polyol, and water, and the amount of water is 0.1 to 5% based on the total amount of the polyol including the new polyol and the regenerated polyol. Therefore, the fluidity of the raw material liquid can be ensured, and it is possible to cope with a complicated refrigerator.

In the refrigerator according to the second aspect of the present invention, the amount of the regenerated polyol is 1 to 50% based on the total amount of the polyol including the new polyol and the regenerated polyol. It becomes a refrigerator that reuses.

Further, the refrigerator according to claim 3 comprises an outer box,
An inner box, a box formed of an outer box and an inner box, a plurality of partition walls separating the box into a plurality of storage rooms, and a raw urethane foam liquid in a space between the outer box and the inner box. It has a plurality of inlets provided on the back of the refrigerator for injecting, and a raw material liquid of urethane foam to be injected from an inlet provided behind a portion where a plurality of partition walls are densely provided has a plurality of partitions. Since the ratio of the contained recycled polyol is larger than that of the urethane foam raw material liquid injected from the injection port provided behind the portion where the wall is provided roughly, the recycled polyol can be used according to the required strength.

Further, the refrigerator according to claim 4 comprises an outer box,
An inner box, a box formed by the outer box and the inner box, a partition wall provided at a position higher than a central portion of the refrigerator that separates the box into two storage rooms, and between the outer box and the inner box. And a plurality of inlets provided on the back of the refrigerator for injecting the urethane foam raw material liquid into the space, wherein the plurality of inlets are provided in the vertical direction of the partition wall, and are injected from the inlet provided in the upward direction. The urethane foam raw material liquid contains a larger proportion of the recycled polyol contained than the urethane foam raw material liquid injected from the injection port provided in the downward direction, so that the content of the recycled polyol matches the form of this refrigerator. The required strength of the refrigerator is also satisfied.

Further, in the refrigerator according to the fifth aspect, since the partition wall is provided in the range of 800 to 1100 mm in height, the storage room near the partition wall becomes easy to use.

Further, the refrigerator according to claim 6 includes an outer box,
An inner box, a box formed of an outer box and an inner box, a first partition wall provided at a position higher than the center of the refrigerator that partitions the box into two storage rooms, a first partition wall and a refrigerator A second partition wall provided between the bottom and the bottom, comprising a plurality of inlets provided on the back of the refrigerator to inject the raw material liquid of the urethane foam into the space between the outer box and the inner box, The inlet is provided in the vertical direction of the first partition wall, and the raw material liquid of the urethane foam injected from the inlet provided in the upward direction is compared with the raw material liquid of the urethane foam injected from the inlet provided in the lower direction. Since the ratio of the regenerated polyol to be contained is large or the same, the content of the regenerated polyol matches the form of the refrigerator, and the required strength of the refrigerator is satisfied.

Further, the refrigerator according to claim 7 includes an outer box,
An inner box, a box formed of an outer box and an inner box, a first partition wall provided at a position higher than the center of the refrigerator that partitions the box into two storage rooms, a first partition wall and a refrigerator The second partition wall provided between the bottom surface, the third partition wall provided between the first partition wall and the second partition wall, and the urethane foam in the space between the outer box and the inner box. A plurality of inlets provided on the back of the refrigerator for injecting the raw material liquid, the plurality of inlets are provided in the up-down direction of the first partition wall, and of the urethane foam to be injected from the inlet provided in the upward direction. Since the raw material liquid has a smaller or the same ratio of the regenerated polyol contained therein as compared to the raw urethane foam liquid injected from the injection port provided in the downward direction, the content of the regenerated polyol suitable for the form of this refrigerator The required strength of the refrigerator is also satisfied.

In the refrigerator according to the eighth aspect, the height of the first partition is set in the range of 800 to 1100 mm and the height of the second partition is set in the range of 300 to 500 mm.
The storage room near the first partition is easy to use, and the storage room near the second partition is easy to use.

Further, the refrigerator according to claim 9 comprises an outer box,
An inner box, a box formed of the outer box and the inner box, a plurality of doors covering the front surface of the box, and injecting the urethane foam raw material liquid into the space between the outer box and the inner box. With a plurality of inlets provided on the back of the refrigerator, the raw material liquid of urethane foam injected from the inlet provided behind the largest door is converted to the raw material liquid of urethane foam injected from the inlets other than the inlet. In comparison, the ratio of the contained recycled polyol is small, so that the recycled polyol can be used without affecting the strength of the refrigerator box.

Further, in the refrigerator according to the tenth aspect, since the raw urethane foam liquid injected from the injection port provided behind the largest door does not contain regenerated polyol, the strength of the refrigerator box is further increased.

A method of manufacturing a refrigerator according to claim 11 is a step of mixing the recycled polyol and a new polyol, and mixing 0.1 to 5% of water with respect to the total amount of the mixed polyol to form a mixed solution. A step of producing the refrigerator by injecting a raw material liquid of the urethane foam containing the mixed liquid into a space provided between the outer box and the inner box of the refrigerator, and filling the foam by foaming. It is easy to adjust the amount of water in the raw material liquid, and a high-strength refrigerator can be manufactured.

Further, a method of manufacturing a refrigerator according to claim 12 includes a step of crushing a box made of urethane foam;
A step of separating urethane foam from the crushed refrigerator, a step of pulverizing the separated urethane foam lump, a step of heating by adding a polyol and a catalyst to the pulverized urethane foam powder, and a step of distilling and filtering the product after heating. A step of producing a recycled polyol, and a step of injecting a raw material liquid of foamed urethane containing the recycled polyol into a space provided between an outer box and an inner box of the refrigerator, foam-filling the same, and manufacturing a refrigerator. As a result, a high quality recycling process can be realized.

[Brief description of the drawings]

FIG. 1 is a flowchart showing a urethane foam regenerating step of a refrigerator.

FIG. 2 is a flowchart showing a mixed form of a recycled polyol and a new polyol.

FIG. 3 is a flowchart showing a mixed form of a recycled polyol and a new polyol.

FIG. 4 is a flowchart showing a mixed form of a recycled polyol and a new polyol.

FIG. 5 is a flowchart showing a mixed form of a recycled polyol and a new polyol.

FIG. 6 is a flowchart showing a mixed form of a recycled polyol and a new polyol.

FIG. 7 is a flowchart showing a mixed form of a recycled polyol and a new polyol.

FIG. 8 is a graph showing a change in compressive strength depending on a mixing ratio of a recycled polyol.

FIG. 9 is a schematic view of a two-door refrigerator.

FIG. 10 is a schematic diagram of a refrigerator according to a refrigerator type.

FIG. 11 is a longitudinal sectional view of the refrigerator.

[Explanation of symbols]

1 polyol, 2 isocyanate, 5 refrigerator, 6
Waste refrigerator, 10 urethane powder, 15 recycled polyol, 16 new polyol, 17 foam stabilizer, 18 catalyst,
19 water, 20 blowing agent, 20 inlet, 25 first partition wall, 26 second partition wall, 27 third partition wall, 28 fourth partition wall.

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3L102 JA01 LB01 LB02 LB13 MA01 MB08 MB09 MB14 MB17 4J034 HA01 NA01 NA02 NA06 QC01 RA15

Claims (12)

[Claims] 1. A refrigerator comprising: an outer box, an inner box, a space between the outer box and the inner box, and a foaming urethane raw material liquid injected into the space and foam-filled. The raw material liquid contains a regenerated polyol, a new polyol, and water, and the amount of the water is 0.1 to 5% based on the total amount of the polyol including the new polyol and the regenerated polyol. Refrigerator. 2. The refrigerator according to claim 1, wherein the amount of the regenerated polyol is 1 to 50% based on the total amount of the polyol including the new polyol and the regenerated polyol. 3. An outer box, an inner box, a box formed by the outer box and the inner box, a plurality of partition walls for partitioning the box into a plurality of storage chambers, A plurality of inlets provided on the back of the refrigerator for injecting the urethane foam raw material liquid into a space between the inner box and the inner box, and provided behind a portion where the plurality of partition walls are densely provided. The urethane foam raw material liquid to be injected from the injection port is compared with the urethane foam raw material liquid to be injected from the injection port provided behind the portion where the plurality of partition walls are coarsely provided. A refrigerator characterized by having a large size. 4. An outer box, an inner box, a box formed by the outer box and the inner box, and a refrigerator provided at a position higher than a central portion of a refrigerator that divides the box into two storage compartments. A partition wall, comprising a plurality of inlets provided on the back of the refrigerator for injecting the urethane foam raw material liquid into the space between the outer box and the inner box, wherein the plurality of inlets are provided in the partition wall. The raw urethane foam raw material liquid that is provided in the up-down direction and is injected from the injection port provided in the upward direction is less than the urethane foam raw material liquid that is injected from the injection port provided in the downward direction, and the ratio of the regenerated polyol contained therein is A refrigerator characterized by being large. 5. The refrigerator according to claim 4, wherein the partition wall is provided in a height range of 800 to 1100 mm. 6. An outer box, an inner box, a box formed by the outer box and the inner box, and a box provided at a position higher than a central portion of a refrigerator that divides the box into two storage compartments. A refrigerator for injecting a urethane foam raw material liquid into a space between the first partition wall, the second partition wall provided between the first partition wall and the refrigerator bottom surface, and the outer box and the inner box. A plurality of inlets provided on the back surface, the plurality of inlets are provided in the vertical direction of the first partition wall, the raw material liquid of urethane foam to be injected from the inlet provided in the upper direction, the lower Compared to the urethane foam raw material liquid injected from the inlet provided in the direction,
A refrigerator characterized in that the ratio of the contained recycled polyol is large or the same. 7. An outer box, an inner box, a box formed by the outer box and the inner box, and a refrigerator provided at a position higher than a central portion of a refrigerator that divides the box into two storage compartments. A first partition wall, a second partition wall provided between the first partition wall and the refrigerator bottom surface, and a third partition wall provided between the first partition wall and the second partition wall. A plurality of inlets provided on the back of the refrigerator for injecting the urethane foam raw material liquid into the space between the outer box and the inner box, wherein the plurality of inlets are located above and below the first partition wall. Provided in the direction, the raw urethane foam liquid injected from the injection port provided in the upward direction, compared to the urethane foam raw material liquid injected from the injection port provided in the downward direction, the ratio of the contained recycled polyol is small ,
Or a refrigerator characterized by being the same. 8. The height of the first partition wall is from 800 to 1100.
mm, the height of the second partition wall is 300 to 500 m
The refrigerator according to claim 6 or 7, wherein the refrigerator is provided in a range of m. 9. An outer box, an inner box, a box formed of the outer box and the inner box, a plurality of doors covering a front surface of the box, and the outer box and the inner box. A plurality of inlets provided at the back of the refrigerator for injecting the urethane foam raw material liquid into the space therebetween, and the urethane foam raw material liquid to be injected from the inlet provided behind the largest door, A refrigerator characterized by containing a smaller proportion of a recycled polyol than a raw urethane foam liquid injected from an inlet other than the inlet. 10. The refrigerator according to claim 9, wherein the urethane foam raw material liquid injected from an injection port provided behind the largest door does not contain a regenerated polyol. 11. A step of mixing a regenerated polyol and a new polyol, a step of mixing 0.1 to 5% of water with respect to the total amount of the mixed polyol to form a mixed solution,
A step of injecting a raw material liquid of the urethane foam containing the mixed liquid into a space provided between an outer box and an inner box of the refrigerator and foam-filling the same to manufacture a refrigerator. Production method. 12. A step of crushing a box made of urethane foam, a step of separating urethane foam lumps from the crushed box, a step of crushing the separated urethane foam, and a step of crushing urethane foam A step of adding a polyol and a catalyst to the powder and heating; a step of distilling and filtering the product after heating to generate a regenerated polyol; and a step of mixing a raw material liquid of the urethane foam containing the regenerated polyol with an outer box of a refrigerator and an inner box. Producing a refrigerator by injecting the mixture into a space provided between the box and foam filling.